Wheel speed sensor assembly with stepped alignment key

Abstract

A wheel speed sensor assembly includes a sensor having a housing configured to be received within a bore in a mounting block such that the sensor is spaced from, and faces, an exciter ring and senses rotation of the exciter ring. The housing extends along a longitudinal axis and defines a key on a radially outer surface having first and second portions having different heights. The first portion is configured to be received within a first keyway that is formed in the mounting block and is in communication with the bore in the mounting block. A clamping sleeve is configured to secure the sensor within the bore in the mounting block. The clamping sleeve defines a bore configured to receive the housing of the sensor and a second keyway in communication with the bore in the clamping sleeve. The second portion of the key is received within the second keyway.

What is claimed is: 
     
       1. A wheel speed sensor assembly, comprising:
 a sensor having a housing configured to be received within a bore in a mounting block that positions the sensor such that the sensor is spaced from, and faces, an exciter ring and senses rotation of the exciter ring, the housing extending along a longitudinal axis and defining a key on a radially outer surface, the key having a first portion having a first height and configured to be received within a first keyway that is formed in the mounting block and is in communication with the bore in the mounting block and a second portion having a second height less than the first height; and, 
 a clamping sleeve configured to secure the sensor within the bore in the mounting block, the clamping sleeve defining a clamping sleeve bore configured to receive the housing of the sensor and a second keyway in communication with the clamping sleeve bore, the second keyway configured to receive the second portion of the key. 
 
     
     
       2. The wheel speed sensor assembly of  claim 1  wherein the second keyway is further configured to receive the first portion of the key. 
     
     
       3. The wheel speed sensor assembly of  claim 1  wherein the key has a rectilinear shape. 
     
     
       4. The wheel speed sensor assembly of  claim 3  wherein the key has a rectangular shape. 
     
     
       5. The wheel speed sensor assembly of  claim 1  wherein the key has a curved surface. 
     
     
       6. The wheel speed sensor assembly of  claim 1  wherein the key is coupled to a body of the housing. 
     
     
       7. The wheel speed sensor assembly of  claim 1  wherein the key and a body of the housing form a unitary structure. 
     
     
       8. The wheel speed sensor assembly of  claim 1  wherein the clamping sleeve includes a first and second alignment tabs defining the second keyway, the first and second alignment tabs circumferentially spaced and extending in a radial direction. 
     
     
       9. The wheel speed sensor assembly of  claim 8  wherein at least a portion of each of the first and second alignment tabs extends radially inwardly into the clamping sleeve bore. 
     
     
       10. The wheel speed sensor assembly of  claim 8  wherein at least a portion of each of the first and second alignment tabs extends radially outwardly and is configured to be received within the first keyway in the mounting block. 
     
     
       11. The wheel speed sensor assembly of  claim 8  wherein a first portion of each of the first and second alignment tabs extends radially inwardly into the clamping sleeve bore and a second portion of each of the first and second alignment tabs extends radially outwardly and is configured to be received within the first keyway in the mounting block. 
     
     
       12. A wheel speed sensor assembly, comprising:
 a sensor having a housing configured to be received within a bore in a mounting block that positions the sensor such that the sensor is spaced from, and faces, an exciter ring and senses rotation of the exciter ring, the housing extending along a longitudinal axis and defining a key on a radially outer surface, the key having a first portion having a first height and configured to be received within a first keyway that is formed in the mounting block and is in communication with the bore in the mounting block and a second portion having a second height less than the first height; and, 
 a clamping sleeve configured to secure the sensor within the bore in the mounting block, the clamping sleeve defining a clamping sleeve bore configured to receive the housing of the sensor and a second keyway in communication with the clamping sleeve bore, the second keyway configured to receive the second portion of the key 
 wherein the second portion of the key tapers. 
 
     
     
       13. The wheel speed sensor assembly of  claim 12  wherein the second portion of the key tapers moving in a direction away from the first portion of the key. 
     
     
       14. The wheel speed sensor assembly of  claim 12  wherein only a part of the second portion of the key tapers. 
     
     
       15. The wheel speed sensor assembly of  claim 12  wherein the clamping sleeve includes a first and second alignment tabs defining the second keyway, the first and second alignment tabs circumferentially spaced and extending in a radial direction. 
     
     
       16. The wheel speed sensor assembly of  claim 15  wherein at least a portion of each of the first and second alignment tabs extends radially inwardly into the clamping sleeve bore. 
     
     
       17. The wheel speed sensor assembly of  claim 15  wherein at least a portion of each of the first and second alignment tabs extends radially outwardly and is configured to be received within the first keyway in the mounting block. 
     
     
       18. The wheel speed sensor assembly of  claim 15  wherein a first portion of each of the first and second alignment tabs extends radially inwardly into the clamping sleeve bore and a second portion of each of the first and second alignment tabs extends radially outwardly and is configured to be received within the first keyway in the mounting block. 
     
     
       19. A wheel speed sensor assembly, comprising:
 a mounting block defining a bore and a first keyway in communication with the bore; 
 a sensor having a housing configured to be received within the bore in the mounting block to position the sensor such that the sensor is spaced from, and faces, an exciter ring and senses rotation of the exciter ring, the housing extending along a longitudinal axis and defining a key on a radially outer surface, the key having a first portion having a first height and configured to be received within the first keyway in the mounting block and a second portion having a second height less than the first height; and, 
 a clamping sleeve configured to secure the sensor within the bore in the mounting block, the clamping sleeve defining a clamping sleeve bore configured to receive the housing of the sensor and a second keyway in communication with the clamping sleeve bore, the second keyway configured to receive the second portion of the key. 
 
     
     
       20. The wheel speed sensor assembly of  claim 19  wherein the first keyway is closed at one end.